Replacing the Batteries on a Dremel Stylus

by ekaggrat in Circuits > Tools

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Replacing the Batteries on a Dremel Stylus

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I had burnt one of the cells in the dremel stylus by overcharging them ( faulty base charger )... I tried looking for replacement batteries on the dremel site but found none for the stylus..

So i looked for similar batteries and found 3.6v single cell 2400 mAh batteries from sanyo which could be a direct replacement for the batteries .

The problem with the replacement cells is that they have to be spot welded to make the complete battery.. 

Since i didnot have a option of doing that i made a holder for the replacemnet cells instead so that the cells could be held together to make the battery

Tools Needed

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multimeter
philips head screwdriver
file
paper knife/ stanley knife
soldering iron
vice

Opening the Dremel

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remove the triangular plastic piece from the front end .... then remove the 3 screws holding the dremel together ...

Carefully unclamp the dremel by inserting a straight screw driver on the side

Gathering the Parts for the Holder

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parts needed :

double sided general copper clad board
3 mm brassPCB spacers 
3.6V lithium ion cells
2 mm screws..

Making the Struts

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assemble the spacers as shown in the image

Making the Base and Top

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Cut the copper board to the size of the batteries. 

drill 2 mm holes on the two edges of the boards

remove the battery board from the original batteries

solder copper plates to the copper boards to make good contact with the batteries

solder the battery board from the original batteries to the top board 

finally bolt the pcb spacer struts to the boards using 2mm screws 

Putting the Holder Together

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assemble the holder together and grind the edges to round them off so that they fit into the dremel

Soldering the New Holder to the Dremel

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solder the top plate to the battery leads in the right orientation

Assembling Back

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assemble the battery holder and insert it back into the dremel...

make sure to orient the battery plate in the right orientation ...

thats all.... if the batteries are inserted in the right orientation the dremel should work....